Methods and apparatus for ophthalmic devices including cycloidally oriented liquid crystal layers

ABSTRACT

This invention discloses methods and apparatus for providing a variable optic insert into an ophthalmic lens. A liquid crystal layer may be used to provide a variable optic function and in some examples, an alignment layer for the liquid crystal layer may be patterned in a cycloidally dependent manner. The patterning may allow for a polarization dependent lens in some examples. An energy source is capable of powering the variable optic insert included within the ophthalmic lens. In some examples, an ophthalmic lens is cast-molded from a silicone hydrogel. The various ophthalmic lens entities may include electroactive liquid crystal layers to electrically control optical characteristics.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/487,888 filed Sep. 16, 2014 which claims the benefit of ProvisionalApplication No. 61/878,723 filed Sep. 17, 2013.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention describes an ophthalmic lens device with a variable opticcapability and, more specifically, in some examples, the fabrication ofan ophthalmic lens with a variable optic insert utilizing liquid crystalelements.

2. Discussion of the Related Art

Traditionally an ophthalmic lens, such as a contact lens or anintraocular lens provided a predetermined optical quality. A contactlens, for example, may provide one or more of the following: visioncorrecting functionality; cosmetic enhancement; and therapeutic effects,but only a set of vision correction functions. Each function is providedby a physical characteristic of the lens. Basically, a designincorporating a refractive quality into a lens provides visioncorrective functionality. A pigment incorporated into the lens mayprovide a cosmetic enhancement. An active agent incorporated into a lensmay provide a diagnostic and/or therapeutic functionality.

To date optical quality in an ophthalmic lens has been designed into thephysical characteristic of the lens. Generally, an optical design hasbeen determined and then imparted into the lens during fabrication ofthe lens, such as, for example through cast molding, or lathing. Theoptical qualities of the lens have remained static once the lens hasbeen formed. However, wearers may at times find it beneficial to havemore than one focal power available to them in order to provide sightaccommodation. Unlike spectacle wearers, who may change spectacles tochange an optical correction, contact wearers or those with intraocularlenses have not been able to change the optical characteristics of theirvision correction without significant effort or the complementing ofspectacles with contact lenses or intraocular lenses.

SUMMARY OF THE INVENTION

Accordingly, the present invention includes innovations relating to avariable optic insert with liquid crystal elements that may be energizedand incorporated into an ophthalmic device, which is capable of changingthe optical quality of the device. Examples of such ophthalmic devicesmay include a contact lens or an intraocular lens. In addition, methodsand apparatus for forming an ophthalmic lens with a variable opticinsert with liquid crystal elements are presented. Some examples mayalso include a cast-molded silicone hydrogel contact lens with a rigidor formable energized insert, which additionally includes a variableoptic portion, wherein the insert is included within the ophthalmic lensin a biocompatible fashion. The formable energized insert may also besandwiched in between independently produced contact lens material suchas hydrogel.

The present invention therefore includes disclosure of an ophthalmiclens with a variable optic insert, apparatus for forming an ophthalmiclens with a variable optic insert, and methods for manufacturing thesame. An energy source may be deposited or assembled onto a variableoptic insert and the insert may be placed in proximity to one, or bothof, a first mold part and a second mold part. A composition comprising areactive monomer mixture (hereafter referred to as a reactive monomermixture) is placed between the first mold part and the second mold part.The first mold part is positioned proximate to the second mold partthereby forming a lens cavity with the energized media insert and atleast some of the reactive monomer mixture in the lens cavity; thereactive monomer mixture is exposed to actinic radiation to form anophthalmic lens. Lenses are formed via the control of actinic radiationto which the reactive monomer mixture is exposed. In some examples, anophthalmic lens skirt or an insert-encapsulating layer comprisesstandard hydrogel ophthalmic lens formulations. Exemplary materials withcharacteristics that may provide an acceptable match to numerous insertmaterials may include, for example, the Narafilcon family (includingNarafilcon A and Narafilcon B), the Etafilcon family (includingEtafilcon A), Galyfilcon A and Senofilcon A.

The methods of forming the variable optic insert with liquid crystalelements and the resulting inserts are important aspects of variousexamples of the invention. In some examples, the liquid crystal may belocated between two alignment layers, which may set the restingorientation for the liquid crystal. In some examples the alignmentlayers may be patterned in various manners. The patterning of thealignment layers may be performed such that the alignment of themolecules in the alignment layer interacts with liquid crystal moleculesto form a smoothly varying cycloidal type pattern from a firstorientation in the center of the lens to a second orientation furtheralong a radial axis, where this pattern repeats. In some examples, theperiod of the repeating pattern may be modulated for various purposessuch a contracting the pattern along the axial direction in a secondorder or parabolic manner. Other contractions or expansions of differentorders of the radial dimension may be possible. The smoothly varyingpattern may be classified as a cycloidal pattern and since theorientation of liquid crystal molecules may be varied in the plane of asurface, the effective index of refraction of light progressing throughthe layer or oriented material may be relatively constant. Nevertheless,the cycloidal pattern of molecules may interact with the light invarious manners and in particular may impart differential phase shiftsto light of right handed versus left handed circular polarization Thealignment layers may be in electrical communication with an energysource through electrodes deposited on substrate layers that contain thevariable optic portion. The electrodes may be energized through anintermediate interconnect to an energy source or directly throughcomponents embedded in the insert.

The energization of the electrode layers may cause a shift in the liquidcrystal from a resting orientation which may be patterned in a cycloidalpattern where the pattern may be called a diffractive waveplate lenspattern to an energized orientation where the cycloidal pattern may benot present. In examples that operate with two levels of energization,on or off, the liquid crystal may only have one energized orientation.The waveplate pattern may be formed into thin layers of liquid crystalmaterial at thicknesses less than the wavelength of visible light.

The resulting alignment and orientation of the molecules may affectlight that passes through the liquid crystal layer thereby causing thevariation in the variable optic insert. For example, the alignment andorientation may act with refractive or diffractive characteristics uponthe incident light. Additionally, the effect may include an alterationof the polarization of the light or impact the phase of light dependingon polarization. Some examples may include a variable optic insertwherein energization alters a focal characteristic of the lens.

In some examples, the liquid crystal layer may be formed in a mannerwherein a polymerizable mixture comprising liquid crystal molecules iscaused to polymerize. The monomer(s) used to form the polymer matrix mayitself contain attached liquid crystal portions. By controlling thepolymerization and including liquid crystal molecules unattached to themonomer compounds a matrix of cross-linked polymer regions may be formedthat encompass regions where the individual liquid crystal molecules arelocated. In some terminology such a combination of cross-linkedpolymerized molecules with interstitial included liquid crystalmolecules may be call a network arrangement. Alignment layers may guidealignment of the liquid crystal molecules which are attached to monomersuch that the network of polymerized material is aligned to the guidingalignment layers. In some examples, there may be a smoothly varyingpattern formed by various manners into the alignment layers which maythen cause the liquid crystal molecules or networks of liquid crystalmaterial to form cycloidal patterns. The attached liquid crystalmolecules are locked into an orientation during the polymerization,however the interstitially located liquid crystal molecules may be freeto orient in space. When no external influence is present, the freeliquid crystal molecules will have their alignment influenced by thematrix of aligned liquid crystal molecules.

Accordingly, in some examples an ophthalmic device may be formed by theincorporation of a variable optic insert comprising liquid crystalmolecules within an ophthalmic device. The variable insert may compriseat least a portion which may be located in the optic zone of theophthalmic device. The variable insert may comprise a front insert pieceand a back insert piece. In some examples, the liquid crystal moleculesmay be aligned into a pattern across at least a first portion of thevariable optic insert that varies with a cycloidal pattern. It may alsobe represented that the orientation of the principal axes of the indexof refraction across at least a first portion of the optic insert mayvary with a cycloidal manner. The locations in liquid crystalorientation aligning with a radial axis across at least a first portionof the optic insert may have a parabolic dependence on a radialdimension. The locations of the alignment with a radial axis, may alsobe termed locations of cycloidal maxima and may be designed such thattheir location relative to the center of the lens may have a primarilyparabolic dependence on the radial distance or radial dimension and insome examples, the location of the cycloidal maxima in the cycloidalpattern may have parabolic and higher order parametric dependence on theradial distance from a center of the optic device.

The front and back insert pieces may have either or both of theirsurfaces curved in various manners, and in some examples the radius ofcurvature of a back surface on the front insert piece may beapproximately the same as the radius of curvature of the front surfaceof the back insert piece. In an alternative manner of description, insome examples, the front insert piece may have a surface with a firstcurvature, and the back insert piece may have a second surface with asecond curvature. In some examples the first curvature may beapproximately the same as the second curvature. An energy source may beincluded into the lens and into the insert, and in some examples theenergy source may be located wherein at least a portion of the energysource is in the non-optic zone of the device.

In some examples the cycloidally patterned layer comprising liquidcrystal material may be capable of causing an optical effectsupplementary to the effect of the different radii of insert surfaces.In some examples the cycloidally patterned layer may assume a curvedshape.

In some examples the ophthalmic device may be a contact lens. In someexamples the ophthalmic device may be an intraocular lens.

In some examples the insert of the ophthalmic device may compriseelectrodes made of various materials, including transparent materialssuch as indium tin oxide (ITO), graphene, and oxides of graphene asnon-limiting examples. A first electrode may be located proximate to aback surface of a front curve piece, and a second electrode may belocated proximate to a front surface of a back curve piece. When anelectric potential is applied across the first and second electrodes, anelectric field may be established across a liquid crystal layer locatedbetween the electrodes. The application of an electric field across theliquid crystal layer may cause free liquid crystal molecules within thelayer to physically align with the electric field. In some examples, thefree liquid crystal molecules may be located in interstitial regionswithin a network of polymer and in some examples the polymer backbonemay contain chemically bound liquid crystal molecules which may bealigned during polymerization by alignment layers. When the liquidcrystal molecules align with the electric field, the alignment may causea change in the optical characteristics that a light ray may perceive asit traverses the layer containing liquid crystal molecules and mayeliminate the cycloidal patterning. A non-limiting example may be thatthe index of refraction may be altered by the change in alignment. Insome examples, the change in optical characteristics may result in achange in focal characteristics of the lens which contains the layercontaining liquid crystal molecules and may cause the elimination of acycloidal characteristic of the layer.

In some examples, the ophthalmic devices as described may include aprocessor.

In some examples, the ophthalmic devices as described may include anelectrical circuit. The electrical circuit may control or directelectric current to flow within the ophthalmic device. The electricalcircuit may control electrical current to flow from an energy source tothe first and second electrode elements.

The insert device may comprise more than a front insert piece and a backinsert piece in some embodiments. An intermediate piece or pieces may belocated between the front insert piece and the back insert piece. In anexample, a liquid crystal containing layer may be located between thefront insert piece and the intermediate piece. The variable insert maycomprise at least a portion which may be located in the optic zone ofthe ophthalmic device. The front, intermediate and back insert piece mayhave either or both of their surfaces curved in various manners, and insome examples the radius of curvature of a back surface on the frontinsert piece may be approximately the same as the radius of curvature ofthe front surface of the intermediate insert piece. An energy source maybe included into the lens and into the insert, and in some examples theenergy source may be located wherein at least a portion of the energysource is in the non-optic zone of the device.

The insert with a front insert piece, a back insert piece and at least afirst intermediate insert piece may comprise at least a first liquidcrystal molecule, and the liquid crystal molecule or molecules may alsobe found in polymer networked regions of interstitially located liquidcrystal molecules. In some examples, there may be a smoothly varyingpattern formed by various manners into alignment layers which may thencause the liquid crystal molecules or networks of liquid crystalmaterial to form cycloidal patterns. In some examples of cycloidalpatterns, the locations in liquid crystal orientation aligning with aradial axis across at least a first portion of the optic insert may havea parabolic dependence on a radial dimension. The cycloidal pattern mayhave a primarily parabolic dependence on the radial distance, and insome examples, the cycloidal pattern may have parabolic and higher orderparametric dependence on the radial distance from a center of the opticdevice.

In some examples with a front insert piece, a back insert piece and atleast a first intermediate insert piece the ophthalmic device may be acontact lens.

In some examples the insert of the ophthalmic device with a front insertpiece, a back insert piece and at least a first intermediate insertpiece may comprise electrodes made of various materials, includingtransparent materials such as ITO as a non-limiting example. A firstelectrode may be located proximate to a back surface of a front curvepiece, and a second electrode may be located proximate to a frontsurface of an intermediate piece. When an electric potential is appliedacross the first and second electrodes, an electric field may beestablished across a liquid crystal layer located between theelectrodes. The application of an electric field across the liquidcrystal layer may cause liquid crystal molecules within the layer tophysically align with the electric field. In some examples, the liquidcrystal molecules may be located in polymer networked regions ofinterstitially located liquid crystal material. When the liquid crystalmolecules align with the electric filed, the alignment may cause achange in the optical characteristics that a light ray may perceive asit traverses the layer containing liquid crystal molecules. Anon-limiting example may be that the index of refraction may be alteredby the change in alignment. In some examples, the change in opticalcharacteristics may result in a change in focal characteristics of thelens which contains the layer containing liquid crystal molecules.

In some examples the intermediate piece may comprise multiple piecesthat are joined together.

In some examples where the insert device may be comprised of a frontinsert piece, a back insert piece and an intermediate piece or pieces, aliquid crystal containing layer may be located between the front insertpiece and the intermediate piece or between the intermediate piece andthe back insert piece. In addition, a polarizing element may be locatedwithin the variable insert device as well. The variable insert maycomprise at least a portion which may be located in the optic zone ofthe ophthalmic device. The front, intermediate and back insert piecesmay have either or both of their surfaces curved in various manners, andin some examples the radius of curvature of a back surface on the frontinsert piece may be approximately the same as the radius of curvature ofthe front surface of the intermediate insert piece. An energy source maybe included into the lens and into the insert and in some examples theenergy source may be located wherein at least a portion of the energysource is in the non-optic zone of the device.

In some examples it may be possible to reference surfaces within thevariable optic insert rather than pieces. In some examples, anophthalmic lens device may be formed where a variable optic insert maybe positioned within the ophthalmic lens device where at least a portionof the variable optic insert may be positioned in the optical zone ofthe lens device. These examples may include a curved front surface and acurved back surface. In some examples the front surface and the backsurface may be configured to form at least one chamber. The ophthalmiclens device may also include an energy source embedded in the insert inat least a region comprising a non-optical zone. The ophthalmic lensdevice may also include a layer containing liquid crystal materialpositioned within the chamber, wherein the layer includes regions ofliquid crystal material aligned in a cycloidal pattern in the plane ofthe local surface of the lens. The ophthalmic lens device may alsoinclude a layer where the locations in liquid crystal orientationaligning with a radial axis across at least a first portion of the opticinsert may have a parabolic dependence on a radial dimension.

In some examples a contact lens device may be formed where a variableoptic insert may be positioned within the ophthalmic lens device whereat least a portion of the variable optic insert may be positioned in theoptical zone of the lens device. These examples may include a curvedfront surface and a curved back surface. In some examples the frontsurface and the back surface may be configured to form at least a firstchamber. The contact lens device may also include a layer containingliquid crystal material positioned within the chamber, wherein the layerincludes regions of liquid crystal material aligned in a cycloidalpattern.

In some examples a contact lens device may be formed where a variableoptic insert may be positioned within the ophthalmic lens device whereat least a portion of the variable optic insert may be positioned in theoptical zone of the lens device. The contact lens device may alsoinclude a layer containing liquid crystal material positioned within thechamber, wherein the layer includes regions of liquid crystal materialaligned in a cycloidal pattern, and wherein at least a first surface ofthe layer may be curved.

In some examples an ophthalmic lens device may be formed where avariable optic insert may be positioned within the ophthalmic lensdevice where at least a portion of the variable optic insert may bepositioned in the optical zone of the lens device. These examples mayinclude a curved front surface and a curved back surface. In someexamples a first curved front surface and a first curved back surfacemay be configured to form at least a first chamber. A second curvedfront surface and a second curved back surface may be configured to format least a second chamber. The ophthalmic lens device may also include alayer containing liquid crystal material positioned within the firstchamber, wherein the layer includes regions of liquid crystal materialaligned in a cycloidal pattern. The ophthalmic lens device may alsoinclude an energy source embedded in the insert in at least a regioncomprising a non-optical zone. In some examples the ophthalmic lens maybe a contact lens. In some examples the ophthalmic lens may be anintraocular lens.

In some examples a contact lens device may be formed where a variableoptic insert may be positioned within the ophthalmic lens device whereat least a portion of the variable optic insert may be positioned in theoptical zone of the lens device. The contact lens may include a curvedfirst front surface and a curved first back surface wherein the firstfront surface and the first back surface are configured to form at leasta first chamber. The contact lens may also include a first layer ofelectrode material proximate to the back surface of the curved firstfront surface. The contact lens may also comprise a second layer ofelectrode material proximate to the front surface of the first backcurve piece. The contact lens may also include a first layer containingliquid crystal material positioned within the first chamber, wherein thelayer includes regions of liquid crystal material aligned in a patternwherein an index of refraction across at least a first portion of thevariable optic insert varies with a radial, wherein the first layercontaining liquid crystal material varies its index of refractionaffecting a ray of light traversing the first layer of liquid crystalmaterial when an electric potential is applied across the first layer ofelectrode material and the second layer of electrode material. Thecontact lens device may additionally include a curved second frontsurface and a curved second back surface wherein the second frontsurface and the second back surface are configured to form at least asecond chamber. The contact lens device may also comprise a third layerof electrode material proximate to the back surface of the curved secondfront surface, and a fourth layer of electrode material proximate to thefront surface of the second back curve piece. A second layer containingliquid crystal material positioned within the second chamber may also beincluded wherein the layer includes regions of liquid crystal materialaligned in a cycloidal pattern, and wherein the second layer containingliquid crystal material varies its index of refraction affecting a rayof light traversing the first layer containing liquid crystal materialwhen an electric potential is applied across the third layer ofelectrode material and the forth layer of electrode material. Theintroduction of an electrical potential across layers of electrodematerial may erase a cycloidal pattern in a liquid crystal layer inproximity to the electrodes. The contact lens may also include an energysource embedded in the insert in at least a region comprising anon-optical zone. The contact lens may also include an electricalcircuit comprising a processor, wherein the electrical circuit controlsthe flow of electrical energy from the energy source to one or more ofthe first, second, third or fourth electrode layers. And, the contactlens' variable optic insert may also alter a focal characteristic of theophthalmic lens.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will beapparent from the following, more particular description of preferredexamples of the invention, as illustrated in the accompanying drawings.

FIG. 1 illustrates exemplary mold assembly apparatus components that maybe useful in implementing some examples of the present invention.

FIGS. 2A and 2B illustrate an exemplary energized ophthalmic lens with avariable optic insert embodiment.

FIG. 3 illustrates a cross sectional view of an ophthalmic lens deviceembodiment with a variable optic insert wherein the variable opticportion may be comprised of cycloidally oriented liquid crystal.

FIGS. 4A and 4B illustrate an exemplary interaction of alignment layersthat may orient liquid crystal molecules in the plane of the surface butwith different axial orientations.

FIG. 5A illustrates an example of a diffractive waveplate according tothe present disclosure.

FIG. 5B illustrates an example of the interaction of circularpolarization components of light with diffractive waveplates.

FIG. 5C illustrates a diffractive waveplate lens example and a model fortransforming the diffractive waveplate example into a diffractivewaveplate lens example.

FIG. 5D illustrates a pattern that may occur when a lens of the type inFIG. 5C is placed between crossed polarizers.

FIG. 5E illustrates how a cycloidal waveplate lens may function based ondifferent polarizations of light.

FIG. 5F illustrates a close-up of a cross section of an example of avariable optic insert wherein the variable optic portion may becomprised of cycloidally oriented liquid crystal layers in anon-energized state.

FIG. 5G illustrates a close-up of a cross section of an example of avariable optic insert wherein the variable optic portion may becomprised liquid crystal layers in an energized state.

FIG. 6A illustrates aspects of methods and apparatus that may be used toform cycloidal waveplate lenses.

FIG. 6B illustrates an alternative embodiment of a variable optic lenscomprising an insert wherein the variable optic portions may becomprised of cycloidal waveplate lens regions of liquid crystalmolecules between shaped insert pieces and polarizing layers.

FIG. 7 illustrates method steps for forming an ophthalmic lens with avariable optic insert which may be comprised of cycloidally alignedregions of liquid crystal molecules between shaped insert pieces.

FIG. 8 illustrates an example of apparatus components for placing avariable optic insert comprised of cycloidally aligned regions of liquidcrystal molecules between shaped insert pieces into an ophthalmic lensmold part.

FIG. 9 illustrates a processor that may be used to implement someexamples of the present invention.

FIG. 10 illustrates a cross sectional view of an ophthalmic lens deviceembodiment with a variable optic insert wherein the variable opticportion may be comprised of cycloidally oriented liquid crystal.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes methods and apparatus for manufacturingan ophthalmic lens with a variable optic insert wherein the variableoptic portion is comprised of a liquid crystal or a composite materialwhich itself includes liquid crystal constituents. In addition, thepresent invention includes an ophthalmic lens with a variable opticinsert comprised of liquid crystal incorporated into the ophthalmiclens.

According to the present invention, an ophthalmic lens is formed with anembedded insert and an energy source, such as an electrochemical cell orbattery as the storage means for the Energy. In some examples, thematerials comprising the energy source may be encapsulated and isolatedfrom an environment into which an ophthalmic lens is placed. In someexamples the energy source may include an electrochemical cell chemistrywhich may be used in a primary or rechargeable configuration.

A wearer-controlled adjustment device may be used to vary the opticportion. The adjustment device may include, for example, an electronicdevice or passive device for increasing or decreasing a voltage outputor engaging and disengaging the energy source. Some examples may alsoinclude an automated adjustment device to change the variable opticportion via an automated apparatus according to a measured parameter ora wearer input. Wearer input may include, for example, a switchcontrolled by wireless apparatus. Wireless may include, for example,radio frequency control, magnetic switching, patterned emanations oflight, and inductance switching. In other examples activation may occurin response to a biological function or in response to a measurement ofa sensing element within the ophthalmic lens. Other examples may resultfrom the activation being triggered by a change in ambient lightingconditions as a non-limiting example.

Variation in optic power may occur when electric fields, created by theenergization of electrodes, causes realignment within the liquid crystallayer thereby shifting the molecules from the resting orientation to anenergized orientation. In other alternative examples, different effectscaused by the alteration of liquid crystal layers by energization ofelectrodes may be exploited such as, for example, changing of the lightpolarization state, particularly, polarization rotation.

In some examples with liquid crystal layers, there may be elements inthe non-optical zone portion of the ophthalmic lens that may beenergized, whereas other examples may not require energization. In theexamples without energization, the liquid crystal may be passivelyvariable based on some exterior factor, for example, ambienttemperature, or ambient light.

An alternative example may derive when the physical lens elements thatcontain the liquid crystal layers are shaped themselves to havedifferent focal characteristics. The electrically variable index ofrefraction of a liquid crystal layer may then be used to introducechanges in the focal characteristics of the lens based on theapplication of an electric field across the liquid crystal layer throughthe use of electrodes. The index of refraction of a liquid crystal layermay be referred to as an effective index of refraction, and it may bepossible to consider each treatment relating to an index of refractionas equivalently referring to an effective index of refraction. Theeffective index of refraction may come, for example, from thesuperposition of multiple regions with different indices of refraction.In some examples, the effective aspect may be an average of the variousregional contributions, while in other examples the effective aspect maybe a superposition of the regional or molecular effects upon incidentlight. The shape that the front containment surface makes with theliquid crystal layer and the shape that the back containment surfacemakes with the liquid crystal layer may determine, to first order, thefocal characteristics of the system. While referring to refractivecharacteristics of the liquid crystal layer, the patterning of theserefractive characteristics may impart to the lens diffractivecharacteristics that are used to effectively alter focal characteristicsof the lens.

In the following sections detailed descriptions of examples of theinvention will be given. The description of both preferred andalternative examples are examples only, and it is understood that tothose skilled in the art that variations, modifications and alterationsmay be apparent. It is therefore to be understood that said examples donot limit the scope of the underlying invention.

Glossary

In this description and claims directed to the presented invention,various terms may be used for which the following definitions willapply:

Alignment layer: as used herein refers to a layer adjacent to a liquidcrystal layer that influences and aligns the orientation of moleculeswithin the liquid crystal layer. The resulting alignment and orientationof the molecules may affect light that passes through the liquid crystallayer. For example, the alignment and orientation may act withrefractive characteristics upon the incident light. Additionally, theeffect may include alteration of the polarization of the light.

Cycloidal: used herein, cycloidal refers to an optical axis orientationpattern resembling the orientation pattern of a line segment connectingopposite points in a circle as the circle moves on a surface. As usedherein, cycloidal also refers to curves resulting from mathematicaltransformations, such as linear and non-linear contraction or expansiontransformations, rotational transformations and the like, performed uponthe pattern of a line segment connecting opposite points in a circle asthe circle moves on a surface.

Electrical Communication: as used herein refers to being influenced byan electrical field. In the case of conductive materials, the influencemay result from or in the flow of electrical current. In othermaterials, it may be an electrical potential field that causes aninfluence, such as the tendency to orient permanent and inducedmolecular dipoles along field lines as an example.

Energized: as used herein refers to the state of being able to supplyelectrical current to or to have electrical energy stored within.

Energized orientation: as used herein refers to the orientation of themolecules of a liquid crystal when influenced by an effect of apotential field powered by an energy source. For example, a devicecontaining liquid crystals may have one energized orientation if theenergy source operates as either on or off. In other examples, theenergized orientation may change along a scale affected by the amount ofenergy applied.

Energy: as used herein refers to the capacity of a physical system to dowork. Many uses within this invention may relate to the said capacitybeing able to perform electrical actions in doing work.

Energy source: as used herein refers to device capable of supplyingenergy or placing a biomedical device in an energized state.

Energy Harvesters: as used herein refers to device capable of extractingenergy from the environment and convert it to electrical energy.

Interstices and Interstitial as used herein refer to regions within theboundaries of a polymer networked layer that are unoccupied by portionsof the polymer and may be locations for other atoms or molecules toreside. Typically, herein, a liquid crystal molecule itself mayco-reside in a region within the polymer network and the space that saidliquid crystal therefore occupies may be classified as an interstice.

Intraocular lens: as used herein refers to an ophthalmic lens that isembedded within the eye.

Lens-Forming Mixture or Reactive Mixture or reactive monomer mixture(RMM): as used herein refers to a monomer or prepolymer material thatmay be cured and crosslinked or crosslinked to form an ophthalmic lens.Various examples may include lens-forming mixtures with one or moreadditives such as: UV blockers, tints, photoinitiators or catalysts, andother additives one might desire in an ophthalmic lens such as, forexample, contact or intraocular lenses.

Lens-Forming Surface: as used herein refers to a surface that is used tomold a lens. In some examples, any such surface may have an opticalquality surface finish, which indicates that it is sufficiently smoothand formed so that a lens surface fashioned by the polymerization of alens-forming mixture in contact with the molding surface is opticallyacceptable. Further, in some examples, the lens-forming surface may havea geometry that is necessary to impart to the lens surface the desiredoptical characteristics, including, for example, spherical, asphericaland cylinder power, wave front aberration correction, and cornealtopography correction.

Liquid Crystal: as used herein refers to a state of matter havingproperties between a conventional liquid and a solid crystal. A liquidcrystal may not be characterized as a solid, but its molecules exhibitsome degree of alignment. As used herein, a liquid crystal is notlimited to a particular phase or structure, but a liquid crystal mayhave a specific resting orientation. The orientation and phases of aliquid crystal may be manipulated by external forces, for example,temperature, magnetism, or electricity, depending on the class of liquidcrystal.

Lithium Ion Cell: as used herein refers to an electrochemical cell whereLithium ions move through the cell to generate electrical energy. Thiselectrochemical cell, typically called a battery, may be reenergized orrecharged in its typical forms.

Media insert or insert: as used herein refers to a formable or rigidsubstrate capable of supporting an energy source within an ophthalmiclens. In some examples, the media insert also includes one or morevariable optic portions.

Mold: as used herein refers to a rigid or semi-rigid object that may beused to form lenses from uncured formulations. Some preferred moldsinclude two mold parts forming a front curve mold part and a back curvemold part.

Ophthalmic Lens or Lens: as used herein refers to any ophthalmic devicethat resides in or on the eye. These devices may provide opticalcorrection or modification, or may be cosmetic. For example, the term“lens” may refer to a contact lens, intraocular lens, overlay lens,ocular insert, optical insert, or other similar device through whichvision is corrected or modified, or through which eye physiology iscosmetically enhanced (e.g. iris color) without impeding vision. In someexamples, the preferred lenses of the invention are soft contact lenseswhich are made from silicone elastomers or hydrogels, which include, forexample, silicone hydrogels and fluorohydrogels.

Optical or optic zone: as used herein refers to an area of an ophthalmiclens through which a wearer of the ophthalmic lens sees.

Power: as used herein refers to work done or energy transferred per unitof time.

Rechargeable or Reenergizable: as used herein refers to a capability ofbeing restored to a state with higher capacity to do work. Many useswithin the present invention may relate to the capability of beingrestored with the ability to flow electrical current at a certain ratefor certain, reestablished time period.

Reenergize or Recharge: as used herein refers to the restoration of anenergy source to a state with higher capacity to do work. Many useswithin the present invention may relate to restoring a device to thecapability to flow electrical current at a certain rate for a certain,reestablished time period.

Released from a mold: as used herein refers to a lens is eithercompletely separated from the mold, or is only loosely attached so thatit may be removed with mild agitation or pushed off with a swab.

Resting orientation: as used herein refers to the orientation of themolecules of a liquid crystal device in its resting, non-energizedstate.

Variable optic: as used herein refers to the capacity to change anoptical quality, for example, the optical power of a lens or thepolarizing angle.

Ophthalmic Lenses

Referring to FIG. 1, an to form ophthalmic devices comprising sealed andencapsulated inserts is depicted. The apparatus includes an exemplaryfront curve mold 102 and a matching back curve mold 101. A variableoptic insert 104 and a body 103 of the ophthalmic device may be locatedinside the front curve mold 102 and the back curve mold 101. In someexamples, the material of the body 103 may be a hydrogel material, andthe variable optic insert 104 may be surrounded on all surfaces by thismaterial.

The variable optic insert 104 may comprise multiple liquid crystallayers (also called layers containing liquid crystal.) Other examplesmay include a single liquid crystal layer, some of which are discussedin later sections. The use of the apparatus 100 may create a novelophthalmic device comprised of a combination of components with numeroussealed regions.

In some examples, a lens with a variable optic insert 104 may include arigid center soft skirt design wherein a central rigid optical elementincluding the layer containing liquid crystal 109 and the layercontaining liquid crystal 110 is in direct contact with the atmosphereand the corneal surface on respective anterior and posterior surfaces.The soft skirt of lens material (typically a hydrogel material) isattached to a periphery of the rigid optical element, and the rigidoptical element may also add energy and functionality to the resultingophthalmic lens.

Referring to FIG. 2A, at 200 a top down and FIG. 2B at 250 a crosssectional depiction of an example of a variable optic insert is shown.In this depiction, an energy source 210 is shown in a periphery portion211 of the variable optic insert 200. The energy source 210 may include,for example, a thin film, rechargeable lithium ion battery or analkaline cell based battery. The energy source 210 may be connected tointerconnect features 214 to allow for interconnection. Additionalinterconnects at 225 and 230 for example may connect the energy source210 to a circuit such as electronic circuit 205. In other examples, aninsert may have interconnect features deposited on its surface.

In some examples, the variable optic insert 200 may include a flexiblesubstrate. This flexible substrate may be formed into a shapeapproximating a typical lens form in a similar manner previouslydiscussed or by other means. However to add additional flexibility, thevariable optic insert 200 may include additional shape features such asradial cuts along its length. There may be multiple electroniccomponents such as that indicated by 205 such as integrated circuits,discrete components, passive components and such devices that may alsobe included.

A variable optic portion 220 is also illustrated. The variable opticportion 220 may be varied on command through the application of acurrent through the variable optic insert which in turn may typicallyvary an electric field established across a liquid crystal layer. Insome examples, the variable optic portion 220 comprises a thin layercomprising liquid crystal between two layers of transparent substrate.There may be numerous manners of electrically activating and controllingthe variable optic component, typically through action of the electroniccircuit 205. The electronic circuit, 205 may receive signals in variousmanners and may also connect to sensing elements which may also be inthe insert such as item 215. In some examples, the variable optic insertmay be encapsulated into a lens skirt 255, which may be comprised ofhydrogel material or other suitable material to form an ophthalmic lens.In these examples the ophthalmic lens may be comprised of the lens skirt255 and an encapsulated variable optic insert 200 which may itselfcomprise layers or regions of liquid crystal material or comprisingliquid crystal material and in some examples the layers may comprisepolymer networked regions of interstitially located liquid crystalmaterial.

A Variable Optic Insert Including Liquid Crystal Elements

Referring to FIG. 3, an ophthalmic lens 360 is shown with an embeddedvariable optic insert 371. The ophthalmic lens 360 may have a frontcurve surface 370 and a back curve surface 372. The variable opticinsert 371 may have a variable optic portion 373 with a liquid crystallayer 374. In some examples, the variable optic insert 371 may havemultiple liquid crystal layers 374 and 375. Portions of the variableoptic insert 371 may overlap with the optical zone of the ophthalmiclens 360.

Referring to FIG. 4A, a depiction of a alignment of liquid crystalmolecules 410 by alignment layer molecules 415 may be depicted in anillustrative manner. As shown, alignment layers may be used to controlthe orientation of liquid crystal molecules relative to a surface thatthe alignment layer is attached to and also in the plane or local planeof that surface. The control of the orientation may itself controlregional effective index of refraction of light progressing through thesurface. As well, the orientation of the liquid crystal molecules in thelocal plane may cause interactions with the electric field vectors oflight passing through the surface Thus, the control of the orientationof the liquid crystal molecules can form a regionally variable effectiveindex of refraction or if many of the molecules are generally orientedin the same manner in the direction perpendicular to the surface thenthe orientation of the molecules within the plane of the local surfaceregion may affect the phase of electromagnetic radiation or light thatmay pass through the region. Numerous manners of orienting the liquidcrystal molecules in the plane may allow for different patterns in theliquid crystal spatial orientation in a programmable manner.

Referring again to FIG. 4A, a close up depiction of an example ofalignment layer molecules 415 in an orienting layer interacting withliquid crystal molecules 410 may be found. In a non-limiting example,the alignment layer molecule may be an Azobenzene moiety. In someexamples, one stabile configuration of the azobenzene moiety may placethe aromatic ring portions of the moiety in a cis-configuration wherethe rings are located on the same side of an intervening double bondedchemical bond. This may be the configuration depicted at 415 and mayresult in a portion of the molecule being oriented parallel to thesurface they are binding to. As depicted the interaction of theexemplary azobenzene moiety with liquid crystal molecules may cause themto align along the axes of the azobenzene moieties. In FIG. 4A thesealignment molecules may be oriented to locate the liquid crystalmolecules parallel to the surface. As shown, in addition within theplane of the surface the molecules are shown to orient liquid crystalmolecules lengthwise across the page.

Referring to FIG. 4B, an alternative orientation may be found. In thisexample, the alignment layer molecules 425 may again be oriented in anexemplary cis configuration that aligns liquid crystal molecules 420parallel to the local surface however now the orientation of thesemolecules then is illustrated to depict that another orientation withinthe plane may have the length of the liquid crystal molecules orientedin and out of the page. By programming the orientation of the alignmentlayer molecules it may be possible to define regions that are orientedat many orientations between that depicted in FIG. 4A and in FIG. 4B.

Ophthalmic Devices Comprising Cycloidal Waveplate Lens

A special variety of polarization holograms; namely, cycloidaldiffractive waveplates (CDW), provide substantially one hundred percentdiffraction efficiency and may be spectrally broadband. The structure ofcycloidal diffractive waveplates, schematically illustrated in FIG. 5A,comprises anisotropic material film 565, wherein the optical axisorientation is continuously rotating in the plane of the film asillustrated by the pattern in the anisotropic material film 565. Nearlyone hundred percent efficiency for visible wavelengths is achieved atfulfillment of a half-wave phase retardation condition typically met inapproximately one micrometer (0.001 mm) thick liquid crystal polymer(LCP) films. Referring again to FIG. 5A, a close up view of theorientation programing that may occur in a cycloidal waveplate designshows the repetitively cycling pattern. In a given axis direction, 563for example which may be referred to as the x axis, the pattern may varyfrom orientation parallel to the axial direction 560 throughorientations towards a perpendicular orientation to the axial direction561 and again back through a parallel orientation to the axial directionat 562.

Such an unusual situation in optics where a thin grating exhibits highefficiency, may be understood by considering a linearly polarized lightbeam of wavelength A incident normally, along the z-axis, on abirefringent film in the x,y plane. If the thickness of the film L andits optical anisotropy, Δn, are chosen such that LΔn=λ/2, and itsoptical axis is oriented at forty-five (45) degrees, angle α, withrespect to the polarization direction of the input beam, thepolarization of the output beam is rotated by ninety (90) degrees, angleβ. This is how half-wave waveplates function. The polarization rotationangle at the output of such a waveplate, β=2α, depends on theorientation of the optical axis d=(dx, dy)=(cos α, sin α). Liquidcrystal materials, both low molecular weight as well as polymeric, allowcontinuous rotation of d in the plane of the waveplate at high spatialfrequencies, α=qx, where the spatial modulation period Λ=2π/q may becomparable to the wavelength of visible light. Polarization of light atthe output of such a waveplate is consequently modulated in space,β=2qx, and the electric field in the rotating polarization pattern atthe output of this waveplate is averaged out, <E>=0, and there is nolight transmitted in the direction of the incident beam. Thepolarization pattern thus obtained corresponds to the overlap of twocircularly polarized beams propagating at the angles ±λ/Λ. Referring toFIG. 5B, an illustration of this effect may be found. At 573, anincident beam comprising polarization components from both circularpolarization patterns may intercept the exemplary cycloidal waveplate570. The incident pattern is imaged into the two propogating angles forexample +λ/Λ at 571 and −λ/Λ at 572. Only one of the diffraction ordersis present in the case of a circularly polarized input beam, the +1^(st)at 571 or −1^(st) at 572, depending on whether the beam is right or lefthanded.

A special variety of cycloidal diffractive waveplates may be illustratedat FIG. 5C. In such an example, the cycloidal diffractive waveplatepattern referred to in FIG. 5A may be further refined in the form factorof intraocular lens insert devices. In FIG. 5C a depiction of theconceptual permutation of the diffractive wave plate of FIG. 5A into anew pattern is depicted. A depiction of the orientation of liquidcrystal molecules when looking down upon the diffractive waveplate ismade in a simplified form 570. The simplified form 570 depicts moleculesoriented parallel 571 to the axis direction 563 as a thin stripe,molecules oriented perpendicular 572 to the axis direction 563 aredepicted with a thick line. In a cycloidal pattern, as shown in FIG. 5A,in between these two lines, the liquid crystal molecules may be modelledto smoothly vary in orientation between the extremes. The spacing of thelines in the simplified form 570 may be roughly linear. At 573, atransformation of the pattern may be made to make a paraboliccontraction to the pattern. Along the axis direction the spacing betweenthe lines will therefore change, as depicted in the line location atsimplified contracted form 574. An illustrative single linerepresentation 575 of the simplified contracted form 574 now representsthe narrow lines as unfilled circles and the thicker lines as filledcircles. This representation may be useful to envision how thecontracted cycloidal pattern may be formed into a closed patter. Anexemplary manner of modelling the special variety of diffractionwaveplate may be to consider rotating 576 the single line representation575 of the contracted cycloidal pattern around an axis. In anotherexample, the special variety of diffraction waveplate may be modelled byconsidering replicating the single line representation 575 around acircular path where each orientation at a particular radial point is thesame around a completed circular path. In the resulting illustration583, the shape is an estimation since it has been portrayed in aflattened manner, but a similar orientation programming shape may occuracross three dimensional surfaces such as lens inserts as well.

The pattern that may result from these transformations may then becaused to occur in a liquid crystal layer by writing the appropriatealignment pattern into neighboring alignment layers. The writing of thealignment pattern may be performed upon a flat surface or upon a foldedsurface such as a subtended portion of a spherical surface. When theliquid crystal or liquid crystal polymer molecules are aligned in such amanner, and the resulting layer is placed between crossed polarizers,light emerging through the combination may form a pattern 592 such asthat seen in FIG. 5D. The dark regions 590 may represent an orientationof the liquid crystal molecules in alignment with either of the crossedpolarizer axes. The light areas 591 may represent regions where themolecules are aligned off the axes of the crossed polarization axeswhere the brightest points may be at roughly forty five degrees toeither crossed polarizer axis. The parabolic aspect of the patterningmay be estimated by the decreasing spacing between white pattern lines.Between consecutive white pattern lines, the cycloidal pattern maycomplete a cycle.

Referring to FIG. 5E, an exemplary illustration of a diffractivewaveplate lens of the type discussed herein, may be found. The focusingeffect may derive from both the physical shape of the lens surface andthe parabolic spacing superimposed over the cycloidal pattern, which mayrelate to a parabolic shape to the phase delay characteristics for lightacross the lens surface. The focusing characteristics may interact in aradial manner in the same model as has been discussed with thediffractive waveplate, where one circular polarization direction may bepropagated at a +1^(st) order and the other at a −1^(st) order. In theexemplary illustration, an object 599 of some kind may be centrallylocated at a point and may be modelled by the exemplary rays 593 and598. As these rays, shown with both circular polarization componentsinteract with the diffractive waveplate lens 597 they may both bemodelled to have a +1^(st) order converged to an image at focal point595 whereas the −1^(st) order may be diverged from a focal point todiverged path 594 and diverged path 596 for the example of the exemplaryrays. Thus a perceived image of an object for unpolarized light may be asuperposition of a focused imaged and a defocussed image.

Such a diffractive waveplate lens structure acts like a lens withadvantages compared to other Liquid Crystal lenses that may include thatdifferent or higher strength of the lens (measured as focal length or indiopters) may be obtained within the same thickness or thinner films. Insome examples, the thickness of the film may be only 1-5 μm. Anotheradvantage of the lens may be the opportunity of switching betweenpositive and negative values for focal power adjustment by the switchingof the polarization of light incident upon the device. In some examples,the use of a liquid crystal phase retardation plate may be used tofacilitate the polarization switching. Decoupling between the lensingaction and switching action may allow versatility in electricalcharacteristics of the system, such as capacitance and powerconsumption, as non-limiting examples. For example, even if the lensitself may be chosen to be thin, the thickness of the Liquid Crystalphase retarder may be chosen to minimize power consumption.

A cycloidal diffractive lens pattern formed within the space between afront insert piece and a back insert piece may form an electricallyactive embedded variable optic insert. Referring to FIG. 5F, a variableoptic insert 500 that may be inserted into an ophthalmic lens isillustrated with an exemplary cycloidally varying index of refractionprogrammed through control of the orientation of the liquid crystallayer 530. The variable optic insert 500 may have a similar diversity ofmaterials and structural relevance as has been discussed in othersections of this specification. In some examples, transparent electrodesat 520 and 545 may be placed on a first transparent substrate 510 and asecond transparent substrate 550 respectively. The first 525 and second540 lens surfaces may be comprised of a dielectric film, and thepatterned alignment layers which may be placed upon the transparentelectrodes or dielectric films respectively. The parabolic patterningsuperimposed upon the cycloidal orientation of the liquid crystal layersmay introduce additional focusing power of the lens element abovegeometric effects.

As shown in FIG. 5G by the application of electric potential toelectrodes in the front and back insert pieces an electric field 532 maybe established across the cycloidally oriented liquid crystal layer.When liquid crystal moieties align with the electric field as depictedat 532, the resulting alignment may render the liquid crystal layer tobecome a spatially uniform film without the special properties of adiffractive waveplate lens. Thus, as a non-limiting example, a patternat 531 that has an optical power may not cause a focusing effect withthe application of an electric field as depicted at 532.

Examples of Diffractive Waveplate Lens Processing

Fabrication of Liquid Crystal and Liquid Crystal polymer diffractivewaveplates may be a multistep process. The technology for printingcycloidal diffractive waveplates from a master waveplate may be fit forlarge-scale production with high quality and large areas. This may becompared to other examples involving holographic equipment which may addcomplexity, cost and stability problems. The printing technique may makeuse of the rotating polarization pattern obtained at the output of themaster cycloidal diffractive waveplate from a linearly or circularlypolarized input beam. The period of the printed waveplates may bedoubled when one uses a linearly polarized input beam. As compared todirect recording in photoanisotropic materials, liquid crystal polymertechnology based on photoalignment may have an advantage based upon thecommercial availability of Liquid Crystal Polymers, for example, fromMerck. A typical Liquid Crystal Polymer of reactive mesogens which maybe referenced in a supplier's (Merck) nomenclature, such as RMS-001C,may be spin coated (typically three thousand (3000) rpm for sixty (60)s) on a photoalignment layer and UV polymerized for approximately ten(10) minutes. Multiple layers may be coated for broadband diffraction orfor adjusting the peak diffraction wavelength.

In some examples an ophthalmic insert may be processed to incorporate awaveplate lens. In some examples a front optic piece may be molded,machined or otherwise formed in concert with a back optic piece to havea narrow gap to receive the liquid crystal material. In some examples,the gap may be as narrow as 1.5 microns. The nature of the desired gapthickness may be a function of the liquid crystal material and itscoefficient of birefringence. A diffractive waveplate thickness may needto fulfill a first order or second order of the following equation—Δn*d=(m _(i)+½)*λtherefore a first order thickness (m_(i)=0) may be on the order of 1-2um where a second order may be multiples of the first order thickness. dmay represent the film thickness, delta n may represent thebirefringence coefficient and lambda the wavelength at the center of thespectrum exposed to the device. The thickness may nevertheless be quitesmall, which may have desirable qualities for the size of the insert. Insome examples, to maintain the thin gap at a uniform thickness, spacersof uniform size may be introduced into the liquid crystal material. Uponfilling into the gap formed between the front optic and rear opticpiece, the space may maintain a minimum gap thickness.

In some examples, the front optic and rear optic may be formed fromTopas as an example. There may be surface treatments of the formed opticpieces that promote adhesion and film quality of electrode materialswhich may be deposited upon the optic pieces. The electrodes may beformed of the various discussed materials; and in an example may becomprised of ITO. In some examples, a dielectric film may be depositedupon the electrode material. An alignment layer may be placed upon theoptic piece by spin coating. Examples of alignment layers may includevarious materials that may be summarized in the coming sections; for anexample the material may include an example from a series of photoalignable azobenzene dyes (PAAD). Examples of the spin coating conditionmay be to rotate an approximately 1 cm diameter piece at a speed of1000-5000 rotations per minute for 10-60 seconds or more.

The optic pieces may be placed together without the presence of anyliquid crystal material between the alignment layers. Next thephotosensitive alignment layers may be patterned. Referring to FIG. 6A adepiction of an exemplary patterning process may be found. At 660 acoherent light sources such as a laser may irradiate a pattern mask. Thecoherent light source may have numerous wavelengths for operation, andfor example may operate at 445 nm. The coherent light may pass through aholographic mask 661 that will pattern the cycloidal pattern as has beenmentioned. The light may be concentrated through a focusing lens 662that may be separated by an adjustable distance from the mask, forexample 2 centimeters. The object of the focusing lens may be focused toa focal point 664 which may for example be about 40 cm. The focusedpattern may intersect the front and back optic combined device 663 whichmay be located at the optic locating distance 666 which may be roughly10 cm from the converging lens for example. The irradiation of the maskupon the photoalignment layer may proceed for a variable amount of timewhich may depend on the nature of the photoalignment layer. In anexample the irradiation time may vary from 5 to 30 minutes at anintensity of incident light of 5-50 mW/cm². The resulting patterned lenspieces may then be filled with a liquid crystal containing material. Insome examples, as mentioned, the liquid crystal material may be acombination of different materials and may comprise liquid crystal,polymer liquid crystal and other such materials including the exemplaryspacer spheres or other spacing devices. The result may be an insertthat comprises a diffractive waveplate lens.

In some examples, an insert may be formed from a front optic piece witha back optic piece in similar manners to the previous example where ahybrid alignment condition is established. In such a condition, one ofthe front or back optic pieces may be patterned in a cycloidal typepatterning whereas the other may be patterned such that the alignmentlayer is aligned all parallel to the surface of the optic piece orperpendicular to the surface of the optic piece. In some examples, thesecond optic piece may be coated with a different alignment materialsuch as in a non-limiting sense octadecyldimethyl(3-trimethoxysilylpropyl) ammonium chloride which may be referred to asDMOAP. The DMAOP may be used to coat the optic piece and after dryingmay form a layer which aligns liquid crystal molecules in a homeotropicpattern, where the length of liquid crystal molecules is orientedperpendicularly to the surface.

Referring to FIG. 6B, an alternative of a variable optic insert 600 thatmay be inserted into an ophthalmic lens is illustrated with second layer620 and first layer 640. In some examples each of the layers maycomprise liquid crystal layers; in other examples at least one of thelayers comprises liquid crystal molecules in a waveplate lens typeconfiguration. As discussed the waveplate lens may focus the twoorientation vectors of circularly polarized light differentially. Onemay be focused while the other may be defocussed. In some examples, itmay be desirable to create a two layer insert where a first layer may bea waveplate lens and the other may be a polarizing filter where thatsecond layer filters out one circular polarization component of incidentlight. In other examples the second film may be configured to convertlight to just one circular polarization component.

Each of the aspects of the various layers around the liquid crystalregion(s) and if different the other layered region may have similardiversity as described in relation to the variable optic insert 500 inFIG. 5F. For exemplary purposes, the first layer 640 may be depicted tohave waveplate lens type programming; whereas the second layer 620 maybe depicted with a different orientation of liquid crystal molecules forthis example. By combining a first liquid crystal based element formedby a first substrate 610, whose intervening layers in the space around620 and a second substrate which may be called an intermediate substrate630 may have a first filtering characteristic, with a second liquidcrystal based element formed by a second surface on the intermediatesubstrate 630, the intervening layers in the space around 640 and athird substrate 650 with a waveplate focusing lens characteristic, acombination may be formed which may allow for an electrically variablefocal characteristic of a lens with the clarity of only focused lightpermitted through the lens; as an example.

At the exemplary variable optic insert 600, a combination of at leastthe waveplate type lens layer of the various types and diversityassociated with the examples at variable optic insert 500 may be formedutilizing three substrate layers. In other examples, the device may beformed by the combination of four different substrates. In suchexamples, the intermediate substrate 630 may be split into two layers.If the substrates are combined at a later time, a device that functionssimilarly to variable optic insert 600 may result. The combination offour layers may present an example for the manufacturing of the elementwhere similar devices may be constructed around both 620 and 640 layerswhere the processing difference may relate to the portion of steps thatdefine alignment features for a liquid crystal element.

Materials

Microinjection molding examples may include, for example, a poly(4-methylpent-1-ene) copolymer resin are used to form lenses with adiameter of between about 6 mm to 10 mm and a front surface radius ofbetween about 6 mm and 10 mm and a rear surface radius of between about6 mm and 10 mm and a center thickness of between about 0.050 mm and 1.0mm. Some examples include an insert with diameter of about 8.9 mm and afront surface radius of about 7.9 mm and a rear surface radius of about7.8 mm and a center thickness of about 0.200 mm and an edge thickness ofabout 0.050 mm.

The variable optic insert 104 illustrated in FIG. 1 may be placed in amold part utilized to form an ophthalmic lens. The material of moldparts may include, for example, a polyolefin of one or more of:polypropylene, polystyrene, polyethylene, polymethyl methacrylate, andmodified polyolefins. Other molds may include a ceramic or metallicmaterial.

A preferred alicyclic co-polymer contains two different alicyclicpolymers. Various grades of alicyclic co-polymers may have glasstransition temperatures ranging from 105° C. to 160° C.

In some examples, the molds of the present invention may containpolymers such as polypropylene, polyethylene, polystyrene, polymethylmethacrylate, modified polyolefins containing an alicyclic moiety in themain chain and cyclic polyolefins. This blend may be used on either orboth mold halves, where it is preferred that this blend is used on theback curve and the front curve consists of the alicyclic co-polymers.

In some preferred methods of making molds according to the presentinvention, injection molding is utilized according to known techniques,however, examples may also include molds fashioned by other techniquesincluding, for example: lathing, diamond turning, forming, or lasercutting.

Typically, lenses are formed on at least one surface of both mold parts;back curve mold 101 and front curve mold 102. However, in some examples,one surface of a lens may be formed from a mold part and another surfaceof a lens may be formed using a lathing method, or other methods.

In some examples, a preferred lens material includes a siliconecontaining component. A “silicone-containing component” is one thatcontains at least one [—Si—O—] unit in a monomer, macromer orprepolymer. Preferably, the total Si and attached 0 are present in thesilicone-containing component in an amount greater than about 20 weightpercent, and more preferably greater than 30 weight percent of the totalmolecular weight of the silicone-containing component. Usefulsilicone-containing components preferably comprise polymerizablefunctional groups such as acrylate, methacrylate, acrylamide,methacrylamide, vinyl, N-vinyl lactam, N-vinylamide, and styrylfunctional groups.

In some examples, the ophthalmic lens skirt, also called aninsert-encapsulating layer, that surrounds the insert may be comprisedof standard hydrogel ophthalmic lens formulations. Exemplary materialswith characteristics that may provide an acceptable match to numerousinsert materials may include, the Narafilcon family (includingNarafilcon A and Narafilcon B), and the Etafilcon family (includingEtafilcon A). A more technically inclusive discussion follows on thenature of materials consistent with the art herein. One ordinarilyskilled in the art may recognize that other material other than thosediscussed may also form an acceptable enclosure or partial enclosure ofthe sealed and encapsulated inserts and should be considered consistentand included within the scope of the claims.

Suitable silicone containing components include compounds of Formula I

where

R¹ is independently selected from monovalent reactive groups, monovalentalkyl groups, or monovalent aryl groups, any of the foregoing which mayfurther comprise functionality selected from hydroxy, amino, oxa,carboxy, alkyl carboxy, alkoxy, amido, carbamate, carbonate, halogen orcombinations thereof; and monovalent siloxane chains comprising 1-100Si—O repeat units which may further comprise functionality selected fromalkyl, hydroxy, amino, oxa, carboxy, alkyl carboxy, alkoxy, amido,carbamate, halogen or combinations thereof;

where b=0 to 500, where it is understood that when b is other than 0, bis a distribution having a mode equal to a stated value;

wherein at least one R¹ comprises a monovalent reactive group, and insome examples between one and 3 R¹ comprise monovalent reactive groups.

As used herein “monovalent reactive groups” are groups that may undergofree radical and/or cationic polymerization. Non-limiting examples offree radical reactive groups include (meth)acrylates, styryls, vinyls,vinyl ethers, C₁₋₆alkyl(meth)acrylates, (meth)acrylamides,C₁₋₆alkyl(meth)acrylamides, N-vinyllactams, N-vinylamides,C₂₋₁₂alkenyls, C₂₋₁₂alkenylphenyls, C₂₋₁₂alkenylnaphthyls,C₂₋₆alkenylphenylC₁₋₆alkyls, O-vinylcarbamates and O-vinylcarbonates.Non-limiting examples of cationic reactive groups include vinyl ethersor epoxide groups and mixtures thereof. In one embodiment the freeradical reactive groups comprises (meth)acrylate, acryloxy,(meth)acrylamide, and mixtures thereof.

Suitable monovalent alkyl and aryl groups include unsubstitutedmonovalent C₁ to C₁₆ alkyl groups, C₆-C₁₄ aryl groups, such assubstituted and unsubstituted methyl, ethyl, propyl, butyl,2-hydroxypropyl, propoxypropyl, polyethyleneoxypropyl, combinationsthereof and the like.

In one example, b is zero, one R¹ is a monovalent reactive group, and atleast 3 R¹ are selected from monovalent alkyl groups having one to 16carbon atoms, and in another example from monovalent alkyl groups havingone to 6 carbon atoms. Non-limiting examples of silicone components ofthis embodiment include 2-methyl-,2-hydroxy-3-[3-[1,3,3,3-tetramethyl-1-[(trimethylsilyl)oxy]disiloxanyl]propoxy]propylester (“SiGMA”), 2-hydroxy-3-methacryloxypropyloxypropyl-tris(trimethylsiloxy)silane, 3-methacryloxypropyltris(trimethylsiloxy)silane(“TRIS”), 3-methacryloxypropylbis(trimethylsiloxy)methylsilane and3-methacryloxypropylpentamethyl disiloxane.

In another example, b is 2 to 20, 3 to 15 or in some examples 3 to 10;at least one terminal R¹ comprises a monovalent reactive group and theremaining R¹ are selected from monovalent alkyl groups having 1 to 16carbon atoms, and in another embodiment from monovalent alkyl groupshaving 1 to 6 carbon atoms. In yet another embodiment, b is 3 to 15, oneterminal R¹ comprises a monovalent reactive group, the other terminal R¹comprises a monovalent alkyl group having 1 to 6 carbon atoms and theremaining R¹ comprise monovalent alkyl group having 1 to 3 carbon atoms.Non-limiting examples of silicone components of this embodiment include(mono-(2-hydroxy-3-methacryloxypropyl)-propyl ether terminatedpolydimethylsiloxane (400-1000 MW)) (“OH-mPDMS”), monomethacryloxypropylterminated mono-n-butyl terminated polydimethylsiloxanes (800-1000 MW),(“mPDMS”).

In another example, b is 5 to 400 or from 10 to 300, both terminal R¹comprise monovalent reactive groups and the remaining R¹ areindependently selected from monovalent alkyl groups having 1 to 18carbon atoms, which may have ether linkages between carbon atoms and mayfurther comprise halogen.

In one example, where a silicone hydrogel lens is desired, the lens ofthe present invention will be made from a reactive mixture comprising atleast about 20 and preferably between about 20 and 70% wt siliconecontaining components based on total weight of reactive monomercomponents from which the polymer is made.

In another embodiment, one to four R¹ comprises a vinyl carbonate orcarbamate of the formula:

wherein: Y denotes O—, S— or NH—;

R denotes, hydrogen or methyl; d is 1, 2, 3 or 4; and q is 0 or 1.

The silicone-containing vinyl carbonate or vinyl carbamate monomersspecifically include:1,3-bis[4-(vinyloxycarbonyloxy)but-1-yl]tetramethyl-disiloxane;3-(vinyloxycarbonylthio) propyl-[tris (trimethylsiloxy)silane];3-[tris(trimethylsiloxy)silyl] propyl allyl carbamate;3-[tris(trimethylsiloxy)silyl] propyl vinyl carbamate;trimethylsilylethyl vinyl carbonate; trimethylsilylmethyl vinylcarbonate, and

Where biomedical devices with modulus below about 200 are desired, onlyone R¹ shall comprise a monovalent reactive group and no more than twoof the remaining R¹ groups will comprise monovalent siloxane groups.

Another class of silicone-containing components includes polyurethanemacromers of the following formulae:(*D*A*D*G)_(a) *D*D*E ¹;E(*D*G*D*A)_(a) *D*G*D*E ¹ or;E(*D*A*D*G)_(a) *D*A*D*E ¹  Formulae IV-VIwherein:

D denotes an alkyl diradical, an alkyl cycloalkyl diradical, acycloalkyl diradical, an aryl diradical or an alkylaryl diradical having6 to 30 carbon atoms,

G denotes an alkyl diradical, a cycloalkyl diradical, an alkylcycloalkyl diradical, an aryl diradical or an alkylaryl diradical having1 to 40 carbon atoms and which may contain ether, thio or amine linkagesin the main chain;

* denotes a urethane or ureido linkage;

_(a) is at least 1;

A denotes a divalent polymeric radical of formula:

R¹¹ independently denotes an alkyl or fluoro-substituted alkyl grouphaving 1 to 10 carbon atoms, which may contain ether linkages betweencarbon atoms; y is at least 1; and p provides a moiety weight of 400 to10,000; each of E and E¹ independently denotes a polymerizableunsaturated organic radical represented by formula:

wherein: R¹² is hydrogen or methyl; R¹³ is hydrogen, an alkyl radicalhaving 1 to 6 carbon atoms, or a —CO—Y—R¹⁵ radical wherein Y is —O—,Y—S— or —NH—; R¹⁴ is a divalent radical having 1 to 12 carbon atoms; Xdenotes —CO— or —OCO—; Z denotes —O— or —NH—; Ar denotes an aromaticradical having 6 to 30 carbon atoms; w is 0 to 6; x is 0 or 1; y is 0 or1; and z is 0 or 1.

A preferred silicone-containing component is a polyurethane macromerrepresented by the following formula:

wherein R¹⁶ is a diradical of a diisocyanate after removal of theisocyanate group, such as the diradical of isophorone diisocyanate.Another suitable silicone containing macromer is compound of formula X(in which x+y is a number in the range of 10 to 30) formed by thereaction of fluoroether, hydroxy-terminated polydimethylsiloxane,isophorone diisocyanate and isocyanatoethylmethacrylate.

Other silicone containing components suitable for use in this inventioninclude macromers containing polysiloxane, polyalkylene ether,diisocyanate, polyfluorinated hydrocarbon, polyfluorinated ether andpolysaccharide groups; polysiloxanes with a polar fluorinated graft orside group having a hydrogen atom attached to a terminal difluoro-substituted carbon atom; hydrophilic siloxanyl methacrylates containingether and siloxanyl linkanges and crosslinkable monomers containingpolyether and polysiloxanyl groups. Any of the foregoing polysiloxanesmay also be used as the silicone containing component in the presentinvention.

Liquid Crystal Materials

There may be numerous materials that may have characteristics consistentwith the liquid crystal layer types that have been discussed herein. Itmay be expected that liquid crystal materials with favorable toxicitymay be preferred and naturally derived cholesteryl based liquid crystalmaterials may be useful. In other examples, the encapsulation technologyand materials of ophthalmic inserts may allow a broad choice ofmaterials that may include the LCD display related materials which maytypically be of the broad categories related to nematic or cholesteric Nor smectic liquid crystals or liquid crystal mixtures. Commerciallyavailable mixtures such as Merck Specialty chemicals Licristal mixturesfor TN, VA, PSVA, IPS and FFS applications and other commerciallyavailable mixtures may form a material choice to form a liquid crystallayer.

In a non-limiting sense, mixtures or formulations may comprise thefollowing liquid crystal materials:1-(trans-4-Hexylcyclohexyl)-4-isothiocyanatobenzene liquid crystal,benzoic acid compounds including (4-Octylbenzoic acid and 4-Hexylbenzoicacid), carbonitrile compounds including(4′-Pentyl-4-biphenylcarbonitrile, 4′-Octyl-4-biphenylcarbonitrile,4′-(Octyloxy)-4-biphenylcarbonitrile,4′-(Hexyloxy)-4-biphenylcarbonitrile,4-(trans-4-Pentylcyclohexyl)benzonitrile,4′-(Pentyloxy)-4-biphenylcarbonitrile, 4′-Hexyl-4-biphenylcarbonitrile),and 4,4′-Azoxyanisole.

In a non-limiting sense, formulations showing particularly highbirefringence of n_(par)−n_(perp)>0.3 at room temperature may be used asa liquid crystal layer forming material. For example, such formulationreferred to as W1825 may be as available from AWAT and BEAM Engineeringfor Advanced Measurements Co. (BEAMCO).

There may be other classes of liquid crystal materials that may beuseful for the inventive concepts here. For example, ferroelectricliquid crystals may provide function for electric field oriented liquidcrystal examples, but may also introduce other effects such as magneticfield interactions. Interactions of electromagnetic radiation with thematerials may also differ.

Alignment Layer Materials

In many of the examples that have been described, the liquid crystallayers within ophthalmic lenses may need to be aligned in variousmanners at insert boundaries. The alignment, for example, may beparallel or perpendicular to the boundaries of the inserts, and thisalignment may be obtained by proper processing of the various surfaces.The processing may involve coating the substrates of the inserts thatcontain the liquid crystal (LC) by alignment layers. Those alignmentlayers are described herein.

A technique commonly practiced in liquid crystal based devices ofvarious types may be the rubbing technique. This technique may beadapted to account for the curved surfaces such as the ones of theinsert pieces used for enclosing the liquid crystal. In an example, thesurfaces may be coated by a Polyvinyl Alcohol (PVA) layer. For example,a PVA layer may be spin coated using a 1 weight percent aqueoussolution. The solution may be applied with spin coating at 1000 rpm fortime such as approximately 60 s, and then dried. Subsequently, the driedlayer may then be rubbed by a soft cloth. In a non-limiting example, thesoft cloth may be velvet.

Photo-alignment may be another technique for producing alignment layersupon liquid crystal enclosures. In some examples, photo-alignment may bedesirable due to its non-contact nature and the capability of largescale fabrication. In a non-limiting example, the photo-alignment layerused in the liquid crystal variable optic portion may be comprised of adichroic azobenzene dye (azo dye) capable of aligning predominantly inthe direction perpendicular to the polarization of linear polarizedlight of typically UV wavelengths. Such alignment may be a result ofrepetitive trans-cis-trans photoisomerization processes.

As an example, PAAD series azobenzene dyes may be spin coated from a 1weight percent solution in DMF at 3000 rpm for 30 s. Subsequently, theobtained layer may be exposed to a linear polarized light beam of a UVwavelength (such as for example, 325 nm, 351 nm, 365 nm) or even avisible wavelength (400-500 nm). The source of the light may takevarious forms. In some examples, light may originate from laser sourcesfor example. Other light sources such as LEDs, halogen and incandescentsources may be other non-limiting examples. Either before or after thevarious forms of light are polarized in the various patterns asappropriate, the light may be collimated in various manners such asthrough the use of optical lensing devices. Light from a laser sourcemay inherently have a degree of collimation, for example.

A large variety of photoanisotropic materials are known currently, basedon azobenzene polymers, polyesthers, photo-crosslinkable polymer liquidcrystals with mesogenic 4-(4-methoxycinnamoyloxy)biphenyl side groupsand the like. Examples of such materials include sulfonic bisazodye SD1and other azobenzene dyes, particularly, PAAD-series materials availablefrom BEAM Engineering for Advanced Measurements Co. (BEAMCO), Poly(vinylcinnamates), and others.

In some examples, it may be desirable to use water or alcohol solutionsof PAAD series azo dyes. Some azobenzene dyes, for example, Methyl Red,may be used for photoalignment by directly doping a liquid crystallayer. Exposure of the azobenzene dye to a polarized light may causediffusion and adhesion of the azo dyes to and within the bulk of theliquid crystal layer to the boundary layers creating desired alignmentconditions.

Azobenzene dyes such as Methyl Red may also be used in combination witha polymer, for example, PVA. Other photoanisotropic materials capable ofenforcing alignment of adjacent layers of liquid crystals may beacceptable are known currently. These examples may include materialsbased on coumarines, polyesthers, photo-crosslinkable polymer liquidcrystals with mesogenic 4-(4-methoxycinnamoyloxy)-biphenyl side groups,poly(vinyl cinnamates), and others. The photo-alignment technology maybe advantageous for examples comprising patterned orientation of liquidcrystal.

In another example of producing alignment layers, the alignment layermay be obtained by vacuum deposition of silicon oxide (SiOx where1<=X<=2) on the insert piece substrates. For example, SiO₂ may bedeposited at low pressure such as ˜10⁻⁶ mbar. It may be possible toprovide alignment features at a nanoscaled size that are injectionmolded into with the creation of the front and back insert pieces. Thesemolded features may be coated in various manners with the materials thathave been mentioned or other materials that may directly interact withphysical alignment features and transmit the alignment patterning intoalignment orientation of liquid crystal molecules.

Ion-beam alignment may be another technique for producing alignmentlayers upon liquid crystal enclosures. In some examples, a collimatedargon ion or focused gallium ion beam may be bombarded upon thealignment layer at a defined angle/orientation. This type of alignmentmay also be used to align silicon oxide, diamond-like-carbon (DLC),polyimide and other alignment materials.

Still further examples may relate to the creation of physical alignmentfeatures to the insert pieces after they are formed. Rubbing techniquesas are common in other Liquid Crystal based art may be performed uponthe molded surfaces to create physical grooves. The surfaces may also besubjected to a post-molding embossing process to create small groovedfeatures upon them. Still further examples may derive from the use ofetching techniques which may involve optical patterning processes ofvarious kinds.

Dielectric Materials

Dielectric films and dielectrics are described herein. By way ofnon-limiting examples, the dielectric film or dielectrics used in theliquid crystal variable optic portion possess characteristicsappropriate to the invention described herein. A dielectric may compriseone or more material layers functioning alone or together as adielectric. Multiple layers may be used to achieve dielectricperformance superior to that of a single dielectric.

The dielectric may permit a defect-free insulating layer at a thicknessdesired for the discretely variable optic portion, for example, between1 and 10 μm. A defect may be referred to as a pinhole, as is known bythose skilled in the art to be a hole in the dielectric permittingelectrical and/or chemical contact through the dielectric. Thedielectric, at a given thickness, may meet requirements for breakdownvoltage, for example, that the dielectric should withstand 100 volts ormore.

The dielectric may allow for fabrication onto curved, conical,spherical, and complex three-dimensional surfaces (e.g., curved surfacesor non-planar surfaces). Typical methods of dip- and spin-coating may beused, or other methods may be employed.

The dielectric may resist damage from chemicals in the variable opticportion, for example the liquid crystal or liquid crystal mixture,solvents, acids, and bases or other materials that may be present in theformation of the liquid crystal region. The dielectric may resist damagefrom infrared, ultraviolet, and visible light. Undesirable damage mayinclude degradation to parameters described herein, for example,breakdown voltage and optical transmission. The dielectric may resistpermeation of ions. The dielectric may prevent electromigration,dendrite growth, and other degradations of the underlying electrodes.The dielectric may adhere to an underlying electrode and/or substrate,for example, with the use of an adhesion promotion layer. The dielectricmay be fabricated using a process which allows for low contamination,low surface defects, conformal coating, and low surface roughness.

The dielectric may possess relative permittivity or a dielectricconstant which is compatible with electrical operation of the system,for example, a low relative permittivity to reduce capacitance for agiven electrode area. The dielectric may possess high resistivity,thereby permitting a very small current to flow even with high appliedvoltage. The dielectric may possess qualities desired for an opticdevice, for example, high transmission, low dispersion, and refractiveindex within a certain range.

Example, non-limiting, dielectric materials, include one or more ofParylene-C, Parylene-HT, Silicon Dioxide, Silicon Nitride, and TeflonAF.

Electrode Materials

Electrodes are described herein for applying an electric potential forachieving an electric field across the liquid crystal region. Anelectrode generally comprises one or more material layers functioningalone or together as an electrode.

The electrode may adhere to an underlying substrate, dielectric coating,or other objects in the system, perhaps with the use of an adhesionpromoter (e.g., methacryloxypropyltrimethoxysilane). The electrode mayform a beneficial native oxide or be processed to create a beneficialoxide layer. The electrode may be transparent, substantially transparentor opaque, with high optical transmission and little reflection. Theelectrode may be patterned or etched with known processing methods. Forexample, the electrodes may be evaporated, sputtered, or electroplated,using photolithographic patterning and/or lift-off processes.

The electrode may be designed to have suitable resistivity for use inthe electrical system described herein, for example, meeting therequirements for resistance in a given geometric construct.

The electrodes may be manufactured from one or more of indium tin oxide(ITO), aluminum-doped zinc oxide (AZO), gold, stainless steel, chrome,graphene, graphene-doped layers and aluminum. It will be appreciatedthat this is not an exhaustive list.

The electrodes may be used to establish an electric field in a regionbetween the electrodes. In some examples, there may be numerous surfacesupon which electrodes may be formed. It may be possible to placeelectrodes on any or all of the surfaces that are defined, and anelectric field may be established in the region between any of thesurfaces upon which electrodes have been formed by application ofelectric potential to at least those two surfaces.

Processes

The following method steps are provided as examples of processes thatmay be implemented according to some aspects of the present invention.It should be understood that the order in which the method steps arepresented is not meant to be limiting and other orders may be used toimplement the invention. In addition, not all of the steps are requiredto implement the present invention and additional steps may be includedin various examples of the present invention. It may be obvious to oneskilled in the art that additional examples may be practical, and suchmethods are well within the scope of the claims.

Referring to FIG. 7, a flowchart illustrates exemplary steps that may beused to implement the present invention. At 701, forming a firstsubstrate layer which may comprise a back curve surface and have a topsurface with a shape of a first type that may differ from the shape ofsurface of other substrate layers. In some examples, the difference mayinclude a different radius of curvature of the surface at least in aportion that may reside in the optical zone. At 702, forming a secondsubstrate layer which may comprise a front curve surface or anintermediate surface or a portion of an intermediate surface for morecomplicated devices. At 703, an electrode layer may be deposited uponthe first substrate layer. The deposition may occur, for example, byvapor deposition or electroplating. In some examples, the firstsubstrate layer may be part of an insert that has regions both in theoptical zone and regions in the non-optic zone. The electrode depositionprocess may simultaneously define interconnect features in someembodiments. In some examples a dielectric layer may be formed upon theinterconnects or electrodes. The dielectric layer may comprise numerousinsulating and dielectric layers such as for example silicon dioxide.

At 704, the first substrate layer may be further processed to add analignment layer upon the previously deposited dielectric or electrodelayer. The alignment layers may be deposited upon the top layer on thesubstrate and then processed in standard manners, for example, rubbingtechniques, to create the grooving features that are characteristic ofstandard alignment layers or by treatment with exposure to energeticparticles or light. Thin layers of photoanisotropic materials may beprocessed with light exposure to form alignment layers with variouscharacteristics. As mentioned previously, in methods to form layers ofliquid crystal wherein polymer networked regions of interstitiallylocated liquid crystal are formed, the methods may not include stepsrelated to the formation of alignment layers.

At 705, the second substrate layer may be further processed. Anelectrode layer may be deposited upon the second substrate layer in ananalogous fashion to step 703. Then in some examples, at 706, adielectric layer may be applied upon the second substrate layer upon theelectrode layer. The dielectric layer may be formed to have a variablethickness across its surface. As an example, the dielectric layer may bemolded upon the first substrate layer. Alternatively, a previouslyformed dielectric layer may be adhered upon the electrode surface of thesecond substrate piece.

At 707, an alignment layer may be formed upon the second substrate layerin similar fashion to the processing step at 704. After 707, twoseparate substrate layers that may form at least a portion of anophthalmic lens insert may be ready to be joined. In some examples at708, the two pieces will be brought in close proximity to each other andthen liquid crystal material may be filled in between the pieces. Theremay be numerous manners to fill the liquid crystal in between the piecesincluding as non-limiting examples, vacuum based filling where thecavity is evacuated and liquid crystal material is subsequently allowedto flow into the evacuated space. In addition, the capillary forces thatare present in the space between the lens insert pieces may aid in thefilling of the space with liquid crystal material. At 709, the twopieces may be brought adjacent to each other and then sealed to form avariable optic element with liquid crystal. There may be numerousmanners of sealing the pieces together including the use of adhesives,sealants, and physical sealing components such as o-rings and snap lockfeatures as non-limiting examples.

In some examples, two pieces of the type formed at 709 may be created byrepeating method steps 701 to 709 wherein the alignment layers areoffset from each other to allow for a lens that may adjust the focalpower of non-polarized light. In such examples, the two variable opticlayers may be combined to form a single variable optic insert. At 710,the variable optic portion may be connected to the energy source andintermediate or attached components may be placed thereon.

At 711, the variable optic insert resulting at step 710 may be placedwithin a mold part. The variable optic insert may or may not alsocomprise one or more components. In some preferred examples, thevariable optic insert is placed in the mold part via mechanicalplacement. Mechanical placement may include, for example, a robot orother automation, such as that known in the industry to placesurface-mount components. Human placement of a variable optic insert isalso within the scope of the present invention. Accordingly, anymechanical placement or automation may be utilized which is effective toplace a variable optic insert with an energy source within a cast moldpart such that the polymerization of a reactive mixture contained by themold part will include the variable optic in a resultant ophthalmiclens.

In some examples, a variable optic insert may be placed in a mold partattached to a substrate. An energy source and one or more components mayalso be attached to the substrate and may be in electrical communicationwith the variable optic insert. Components may include for example,circuitry to control power applied to the variable optic insert.Accordingly, in some examples a component includes control mechanism foractuating the variable optic insert to change one or more opticalcharacteristics, such as, for example, a change of state between a firstoptical power and a second optical power.

In some examples, a processor device, microelectromechanical system(MEMS), nanoelectromechanical system (NEMS) or other component may alsobe placed into the variable optic insert and in electrical contact withthe energy source. At 712, a reactive monomer mixture may be depositedinto a mold part. At 713, the variable optic insert may be positionedinto contact with the reactive mixture. In some examples the order ofplacement of variable optic and depositing of monomer mixture may bereversed. At 714, the first mold part is placed proximate to a secondmold part to form a lens-forming cavity with at least some of thereactive monomer mixture and the variable optic insert in the cavity. Asdiscussed above, preferred examples include an energy source and one ormore components also within the cavity and in electrical communicationwith the variable optic insert.

At 715, the reactive monomer mixture within the cavity is polymerized.Polymerization may be accomplished, for example, via exposure to one orboth of actinic radiation and heat. At 716, the ophthalmic lens isremoved from the mold parts with the variable optic insert adhered to orencapsulated within the insert-encapsulating polymerized material makingup the ophthalmic lens.

Although the invention herein may be used to provide hard or softcontact lenses made of any known lens material, or material suitable formanufacturing such lenses, preferably, the lenses of the invention aresoft contact lenses having water contents of about 0 to about 90percent. More preferably, the lenses are made of monomers containinghydroxy groups, carboxyl groups, or both or be made fromsilicone-containing polymers, such as siloxanes, hydrogels, siliconehydrogels, and combinations thereof. Material useful for forming thelenses of the invention may be made by reacting blends of macromers,monomers, and combinations thereof along with additives such aspolymerization initiators. Suitable materials include, withoutlimitation, silicone hydrogels made from silicone macromers andhydrophilic monomers.

Apparatus

Referring now to FIG. 8, automated apparatus 810 is illustrated with oneor more transfer interfaces 811. Multiple mold parts, each with anassociated variable optic insert 814 are contained on a pallet 813 andpresented to transfer interfaces 811. Examples, may include, for examplea single interface individually placing variable optic insert 814, ormultiple interfaces (not shown) simultaneously placing variable opticinserts 814 into the multiple mold parts, and in some examples, in eachmold part. Placement may occur via vertical movement 815 of the transferinterfaces 811.

Another aspect of some examples of the present invention includesapparatus to support the variable optic insert 814 while the body of theophthalmic lens is molded around these components. In some examples thevariable optic insert 814 and an energy source may be affixed to holdingpoints in a lens mold (not illustrated). The holding points may beaffixed with polymerized material of the same type that will be formedinto the lens body. Other examples include a layer of prepolymer withinthe mold part onto which the variable optic insert 814 and an energysource may be affixed.

Processors Included in Insert Devices

Referring now to FIG. 9, a controller 900 is illustrated that may beused in some examples of the present invention. The controller 900includes a processor 910, which may include one or more processorcomponents coupled to a communication device 920. In some examples, acontroller 900 may be used to transmit energy to the energy sourceplaced in the ophthalmic lens.

The controller may include one or more processors, coupled to acommunication device configured to communicate energy via acommunication channel. The communication device may be used toelectronically control one or more of the placement of a variable opticinsert into the ophthalmic lens or the transfer of a command to operatea variable optic device.

The communication device 920 may also be used to communicate, forexample, with one or more controller apparatus or manufacturingequipment components.

The processor 910 is also in communication with a storage device 930.The storage device 930 may comprise any appropriate information storagedevice, including combinations of magnetic storage devices (e.g.,magnetic tape and hard disk drives), optical storage devices, and/orsemiconductor memory devices such as Random Access Memory (RAM) devicesand Read Only Memory (ROM) devices.

The storage device 930 may store a program 940 for controlling theprocessor 910. The processor 910 performs instructions of the program940, and thereby operates in accordance with the present invention. Forexample, the processor 910 may receive information descriptive ofvariable optic insert placement, processing device placement, and thelike. The storage device 930 may also store ophthalmic related data inone or more databases 950, 960. The database 950 and 960 may includespecific control logic for controlling energy to and from a variableoptic lens.

Intraocular Lenses

Referring to FIG. 10, an intraocular device 1060 is shown in referenceto an exemplary eye in cross section. An inset 1070 depicts a region ofthe intraocular device comprising liquid crystal material 1071. A firstsubstrate 1072 and a second substrate 1073 may be coated with variouslayers as discussed herein including electrodes, dielectrics andalignment layers. Portions of the intraocular device 1070 may overlapwith the optical zone of the lens 1060. The first substrate 1072 and thesecond substrate 1073 are shown in an exemplary sense as flat surfaces,however in some examples they may assume a curved shape as well. Theliquid crystal material 1071 is illustrated in such a manner to reflecta local region of liquid crystal material oriented in a cycloidalpattern according to the current disclosure.

In this description, reference has been made to elements illustrated inthe figures. Many of the elements are depicted for reference to depictthe examples of the inventive art for understanding. The relative scaleof actual features may be significantly different from that as depicted,and variation from the depicted relative scales should be assumed withinthe spirit of the art herein. For example, liquid crystal molecules maybe of a scale to be impossibly small to depict against the scale ofinsert pieces. The depiction of features that represent liquid crystalmolecules at a similar scale to insert pieces to allow forrepresentation of factors such as the alignment of the molecules istherefore such an example of a depicted scale that in actual examplesmay assume much different relative scale.

Although shown and described in what is believed to be the mostpractical and preferred examples, it is apparent that departures fromspecific designs and methods described and shown will suggest themselvesto those skilled in the art and may be used without departing from thespirit and scope of the invention. The present invention is notrestricted to the particular constructions described and illustrated,but should be constructed to cohere with all modifications that may fallwithin the scope of the appended claims.

What is claimed is:
 1. An intraocular lens device with a variable opticinsert positioned within at least a portion of an optical zone of theintraocular lens device, wherein the variable optic insert comprises: afront curve piece, at least a first intermediate curve piece and a backcurve piece, wherein a back surface of the front curve piece has a firstcurvature and a front surface of the first intermediate curve piece hasa second curvature; an energy source embedded in the insert in at leasta region comprising a non-optical zone; and the variable optic insertcomprising a layer containing liquid crystal material, wherein the layerincludes regions of liquid crystal material aligned in a pattern acrossat least a first portion of the variable optic insert that varies with acycloidal pattern, wherein locations of orientations in liquid crystalorientation aligning with a radial axis across at least a first portionof the optic insert has a parabolic dependence on a radial dimension. 2.The intraocular lens device of claim 1 wherein the first curvature isapproximately the same as the second curvature.
 3. The intraocular lensdevice of claim 2 wherein the lens includes a polarizing component. 4.The intraocular lens device of claim 3 further comprising: a first layerof electrode material proximate to the front curve piece; and a secondlayer of electrode material proximate to one or more of the intermediatecurve piece and the back curve piece.
 5. The intraocular lens device ofclaim 3 further comprising: a first layer of electrode materialproximate to the front curve piece; and a second layer of electrodematerial proximate to the intermediate curve piece.
 6. The intraocularlens device of claim 5 wherein the layer containing liquid crystalmaterial varies its index of refraction affecting a ray of lighttraversing the layer containing liquid crystal material when an electricpotential is applied across the first layer of electrode material andthe second layer of electrode material.
 7. The intraocular lens deviceof claim 6 wherein the variable optic insert alters a focalcharacteristic of the lens.
 8. The intraocular lens device of claim 7further comprising an electrical circuit, wherein the electrical circuitcontrols a flow of electrical energy from the energy source to the firstand second electrode layers.
 9. The intraocular lens device of claim 8wherein the electrical circuit comprises a processor.